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introduction + Catalina air box #778541 07/13/19 10:05 am
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I´m new to this forum and want to introduce myself.
My name is Rico and i´m from Germany, so please apologize my english. I own a small collection of british motorcycles a 1928 AJS 500 sidecar, a 1928 Royal Enfield 1000cc v-twin, a 1930 RE 500 OHV, a BSA B50.
My newest projekt is a BSA Gold STar scrambler, i have a GS frame and DBD34 engine, central oil tank...
I´ll try to build a catalina air filter box but i don´t know the dimensions. I tryed the search of this forum but couldn´t find something.
Maybe anybody can help me out with the dimensions?

Cheers, Rico

Last edited by vintagebike; 07/13/19 10:13 am.
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Re: introduction + Catalina air box [Re: vintagebike] #778551 07/13/19 3:01 pm
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Originally Posted by vintagebike
Maybe anybody can help me out with the dimensions?
I'd like to help, but the design isn't quite a simple as it might appear. Although the basic box is just a rectangular cuboid, the air tube at the top exits at an angle and is further kinked. The cover is just a bent piece of sheet metal, but the positions of the holes have to align with screws welded in the box, and one end of the cover is angled. Anyway, while the airbox isn't extraordinarily complicated, producing an accurate "engineering drawing" of such a structure would take a good bit of time.

Re: introduction + Catalina air box [Re: vintagebike] #778556 07/13/19 3:21 pm
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Thanks for your help, i only need basic measurements like lenght, width and depth. and maybe the diameter of the intake tube. angles etc. i fit on the bike.
I´ve seen a lot of pictures of this airbox, so i think i can replikate it good enough for me with these basic measurements.
Thanks,Rico

Last edited by vintagebike; 07/13/19 3:24 pm.
Re: introduction + Catalina air box [Re: vintagebike] #778558 07/13/19 3:35 pm
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Originally Posted by vintagebike
i only need basic measurements like lenght, width and depth. and maybe the diameter of the intake tube. angles etc.
I'll see what I can do later today. However, my Catalina is next to another bike so access is limited. If it turns out to be impossible to make the measurements today, and if no one else provides them in the mean time, there's a good chance I'll have the bike on a lift in another week or so where it will be possible to make the measurements.

Re: introduction + Catalina air box [Re: vintagebike] #778566 07/13/19 6:14 pm
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Hello Rico,

Welcome to this forum.
I happen to have just removed the air filter box from my offroad BSA and have taken some pics and measurements. See: https://postimg.cc/gallery/30ex2lp0o/
If this doesn't work, send me an email at [email protected] and I'll post the pics to you directly.

Regards,
Hans

Re: introduction + Catalina air box [Re: vintagebike] #778567 07/13/19 6:37 pm
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Hans,
That´s great. Thank you very much. That helps a lot

Regards, Rico

Re: introduction + Catalina air box [Re: vintagebike] #779142 07/19/19 6:53 pm
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the box is almost finished. tomorrow i´ll make the lid...
[Linked Image]
[Linked Image]
[Linked Image]

Re: introduction + Catalina air box [Re: vintagebike] #779230 07/20/19 4:08 pm
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Nice - and fast - work!

Re: introduction + Catalina air box [Re: vintagebike] #779241 07/20/19 7:54 pm
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Please continue showing your progress on this project....AND the finished result.

Re: introduction + Catalina air box [Re: vintagebike] #779242 07/20/19 7:54 pm
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Please continue showing your progress on this project....AND the finished result.

Re: introduction + Catalina air box [Re: vintagebike] #779243 07/20/19 8:04 pm
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today i made the lid and the filters. i started turning the nuts, but i couldn´t find the tool for the crosses.
[Linked Image]
[Linked Image]

can anybody help me please with the tube diameter?


Last edited by vintagebike; 07/21/19 5:42 am.
Re: introduction + Catalina air box [Re: vintagebike] #779296 07/21/19 2:52 pm
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Originally Posted by vintagebike
can anybody help me please with the tube diameter?
The tube has a 2.27" OD and is made of 0.047"-thick steel.

For what it's worth, yesterday I checked the air flow of my Catalina's filter box assembly with the head still on the flow bench, i.e. I measured the total flow from the outside air, through the head with the valve opened to 0.46", and into the cylinder. I'll later check the filter assembly by itself, once I remove the head and cylinder from the flow bench. All the following measurements were done at a test pressure of 5" H2O:

CFM
84.0 head with radiused inlet guide
75,7 bare head
68.5 head with 1-5/32" Monobloc without an inlet trumpet
66.5 with filter assembly attached but without any filter material in it
63.7 with oiled UNI BF-5 red coarse foam filter material
61.8 with original BSA filter material (of unknown amount of prior use)

Using the values with the foam in place, what this says is the filter only reduces the air flow by 7% compared with having no filter at all.

Re: introduction + Catalina air box [Re: vintagebike] #779299 07/21/19 4:22 pm
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Today I found the tool and finished the nuts.
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]

Thank you magnetoman, that seems, that the bike willrun fine with the filter..

Re: introduction + Catalina air box [Re: vintagebike] #779300 07/21/19 4:48 pm
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I can't help wondering if a spring
Under those knurled nuts wouldn't help
Keep the nuts in place
Without the need to safety wire ?

Re: introduction + Catalina air box [Re: vintagebike] #779337 07/21/19 11:03 pm
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Either a spring washer or a safety wire is a good idea - I once lost one of the original knurled nuts on the road, having neither, and had to replace it with a winged nut, not being able to find an original one.

Re: introduction + Catalina air box [Re: vintagebike] #779736 07/26/19 7:34 am
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some progress made
[Linked Image]
i build the front engine plates, installed new bushings in the swingarm. they are now non rubber bushings. i also made a bigger swingarm axle, is now 18mm.
i wanted to install new bushings and fork stanchions, but on one side the bushings doesn´t fit. a closer look showed why. a former owner pressed the fork slider in a vice an made some dents inside the fork slider. so i had to lap the inside to made the bushings fit. i turned a lapping tool in my lathe and lapped it with the drill press.

Last edited by vintagebike; 07/26/19 7:28 pm.
Re: introduction + Catalina air box [Re: vintagebike] #779742 07/26/19 12:42 pm
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Note that the two knobs that hold the cover have a slight 'dome' to them.

Note also: that TWO clips hold the box to the frame in the front, and one "L"-shaped brace connects the back of the box to the upper rear shock absorber mount.

Re: introduction + Catalina air box [Re: Irish Swede] #779785 07/26/19 7:28 pm
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thanks for the hints, the nuts have the "domes". i found some good pictures with measurements in this forum and made them like shown in the pictures. also thankfully hans made some good pictures, that show all brackets and mountings. i first have to install the motor before i can work on on the airbox.

Re: introduction + Catalina air box [Re: vintagebike] #779794 07/26/19 9:20 pm
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Also note that the choke lever will be located on the LEFT side of the frame, opposite the air box, and should clamp around the frame, what the British call a "scissors mount."
You will see one of them on eBay from time to time, but almost always it will be an A-10 choke lever, which mounted on the right side of the frame, where your air box will be.
The proper one will APPEAR to be a "right-hand" choke lever which would exit the cable to the LEFT,
However, as it mounts on the LEFT side of the FRAME (not the handlebars) it sends the choke cable from what is now the lever's TOP, to the RIGHT and to the carburetor.

I learned this "the hard way."

Re: introduction + Catalina air box [Re: Irish Swede] #779798 07/26/19 10:00 pm
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Originally Posted by Irish Swede
Also note that the choke lever will be located on the LEFT side of the frame, opposite the air box, and should clamp around the frame, what the British call a "scissors mount."
You will see one of them on eBay from time to time, but almost always it will be an A-10 choke lever, which mounted on the right side of the frame, where your air box will be.
The proper one will APPEAR to be a "right-hand" choke lever which would exit the cable to the LEFT,
However, as it mounts on the LEFT side of the FRAME (not the handlebars) it sends the choke cable from what is now the lever's TOP, to the RIGHT and to the carburetor.

I learned this "the hard way."




It's also a 1" lever to fit the frame tube. Handlebar mounted ones are 7/8".


Bill B...


Boomer
Re: introduction + Catalina air box [Re: vintagebike] #781517 08/15/19 7:06 am
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[Linked Image from s18.directupload.net]

i finished the wheels, forks, mudguards and some other stuff..

Last edited by vintagebike; 08/15/19 7:07 am.
Re: introduction + Catalina air box [Re: vintagebike] #781540 08/15/19 3:14 pm
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Very handsome build. Congratulations. Can't wait to see the finished bike.

Re: introduction + Catalina air box [Re: vintagebike] #783745 09/08/19 1:28 am
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Do you still need information? I have dimensioned drawings of the air box, cover, and hardware. Give me your email address and I will send them to you. [email protected]

Re: introduction + Catalina air box [Re: vintagebike] #790381 11/17/19 9:12 pm
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Thank you, but i already finished the aircleaner..

After lots of welding and grinding it begins to look like a motorcycle

[Linked Image from s19.directupload.net]

[Linked Image from s19.directupload.net]

Re: introduction + Catalina air box [Re: vintagebike] #796297 01/22/20 5:23 pm
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I made some progress with the bike. After i found a nice magneto, i decided to build the Goldie in ISDT style. I found some pictures of bikes which are prepared for the ISDT, and i build some special parts like pressed air bottle or chain oiler. I also modified the exhaust pipe, looks better now i think.

[Linked Image from s19.directupload.net]

[Linked Image from s19.directupload.net]

[Linked Image from s19.directupload.net]

[Linked Image from s19.directupload.net]

Now I´m looking for an AMAL 1038 carb. Can´t find one in Europe, maybe you can help me?

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